PileForm F. Pile Jacket Installation Guide FiveStarProducts.com TECHNICAL SUPPORT

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1 TECHNICAL SUPPORT FiveStarProducts.com Pile Jacket Installation Guide

2 -2- STEP 1 1. Clean existing pilings using a minimum of 4,000 psi high-pressure water blast or other mechanical means of cleaning piles of marine growth, rust, and other contaminants. 2. Repair structurally unsound sections with splice plates and/or patches. As directed by engineer, fill any gaps/joints with Five Star Marine Injection Gel, RS Anchor Gel or Five Star Marine Splash Zone Compound. 3. To increase mechanical bond of cementitious grout when encasing piles, mechanically anchor rebar or studs to pile. Length of protrusion depends on annulus specified by the engineer. When encasing steel, engineer may choose to weld studs at equally spaced intervals along the pile length and around the circumference. When using epoxy grout with its higher bond strength, an engineer may choose not to use the preceding mechanical bonding methods. Pile Jacket Installation Guide

3 Pile Jacket Installation Guide STEP 2 (Optional) 1. Cut the appropriate sized hole into jacket to match the diameter of the Pump Port using a diamond-tipped core hole saw. Space Pump Port holes approximately every 5 (1.5 m), or as specified, alternating hole placement on opposite sides. Adhere threaded Pump Port to jacket using Five Star Marine HP Anchor Gel or Five Star Marine RS Anchor Gel and allow adhesive to fully cure. STEP 3 1. Place FRP Jackets to desired elevation and secure with banding straps. Apply epoxy gel to all vertical or horizontal seams and secure using stainless steel self tapping/drilling screws if joining more than one section. Additional 5/16 stainless steel lag bolts can be placed at intervals around the circumference and every 18 inches across the FRP Jackets to create a mechanical attachment between the FRP Jackets and the new grout. This will also prevent the FRP Jackets from pulling away from fill at a later time. FRP Jackets must be secured at the top and bottom of the forms to prevent sagging. 2. Seal the open end of the FRP Jackets using either soffit assemblies designed by the engineer, or FRP Jackets can be manufactured with 3 upset cavity at the bottom of the form which will hold a 3 x 3/8-3/4 neoprene foam seal which will create seal between the jacket and the pile after banding straps are tensioned in place. Next, install external bracing for the pile. The bracing is to be determined by the engineer.

4 - 4 - Pile Jacket Installation Guide STEP 4 1. Once bottom seal is established and bracing is in place, begin filling the FRP Jackets with a suitable engineered fill repair material (Five Star Marine Underwater Cementitious Grout, Five Star Marine Pile Jacket Grout, Five Star Marine Pile Jacket Grout LPL, or Five Star Marine Pile Jacket Grout HP) using one of two methods: a. Use a peristaltic pump and start pumping from the bottom via pumping ports. Once fill material is observed at level of next highest port, close valve on lower port and move to next port. METHOD 1 b. Use the pour method by pouring the material from the top of the jacket starting at one end and moving to the other. In many cases pouring from both sides is used to ensure even filling. Continue filling the FRP Jackets until repair material reaches within 1 inch of top and then stop. METHOD 2

5 Pile Jacket Installation Guide STEP 5 1. After the initial set of the fill material, fill the remaining 1 inch. This will seal the top of the jackets preventing any water from getting between FRP Jacket and fill, and will prevent any problems as a result of freeze/thaw. Then, using Five Star Marine Splash Zone Compound, create a 45 bevel from the top of the filled jackets to the existing piles. This will create a run-off and additional seal so that no water gets trapped on the top of the installation. 2. After the epoxy grout is set, strip off external bracing. Although, in most cases, jackets are translucent which enables the workers to watch encapsulation material fill the entire jacket on all sides, have inspection workers check to ensure the entire pile jacket has been filled and that no voids exist under the jackets is recommended. If the decision has been made by the engineer to use removable FRP Jackets, they can be stripped off at this time.

6 - 6 - Pile Jacket Installation Guide NOTE: Leaving FRP Jackets in place can add as much as years to the life of the repair. For recommendations and help with designing a repair or making a choice of the right Five Star Marine product to specify please contact the Five Star Marine Engineering and Technical Service Center at

7 Pile Jacket Installation Guide NOTES

8 Five Star Marine the manufacturer most trusted to provide the total solution. WARRANTY Five Star Marine, Inc. warrants that at the time and place we make shipment, our materials will be of good quality and will conform to our published specifications in force on the date of acceptance of the order. THE FOREGOING WARRANTY SHALL BE EXCLUSIVE AND IN LIEU OF ANY OTHER WARRANTY, EXPRESS OR IMPLIED WARRANTIES OF MERCHANTABILITY AND FIT- NESS FOR A PARTICULAR PURPOSE AND ALL OTHER WARRANTIES OTHERWISE ARISING BY OPERATION OF LAW, COURSE OF DEALING, CUSTOM OR TRADE OR OTHERWISE. As the exclusive remedy for breach of this Warranty, we will replace defective materials, provided, however, that the buyer examines the materials when received and promptly notify in writing of any defect before the materials are used or incorporated into a structure. Twelve (12) months after Five Star Marine, Inc. has shipped the materials, all our Warranty and other duties with respect to the quality of the materials delivered shall conclusively be presumed to have been satisfied, all liability therefore terminates, and not acting for breach of any duties may thereafter commence. Five Star Marine, Inc. shall in no event be liable for consequential damages. Unless otherwise agreed to in writing, no warranty is made with respect to materials not made by Five Star Marine, Inc. We cannot warranty or in any way guarantee any particular method of use of application or the performance of materials under any particular condition. Neither this Warranty nor our liability may be extended or amended by our sales people, distributors or representatives or by any sales information or drawings. Five Star Marine, Inc. 60 Parrott Drive Shelton, CT USA Tel: Five Star Products, Inc Rev B TECHNICAL SUPPORT FiveStarProducts.com